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Design Recommendations - For Pump Stations With Large Centrifugal Flygt Wastewater Pumps
Design Recommendations - For Pump Stations With Large Centrifugal Flygt Wastewater Pumps
Sump dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Required sump volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Minimum stop levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation tips for submerged pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation tips for dry installed submersible pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Systems Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
This brochure is intended to help application engineers, Operating costs can be reduced with the help of effective
designers, planners, and users of sewage and stormwater planning and suitable operation schedules.
systems who are incorporating submerged submersible
and dry installed Flygt pumps into their design. Xylem personnel and publications are available to offer
guidance in these areas. Transient analysis such as air
A proper design of the pump sump in such installations is chamber dimensioning, valve selection, etc. should also
crucial. Two important design requirements to be met are: be considered in wastewater pump station design. These
the prevention of significant quantities of air from reaching matters are not addressed in this brochure, but we can offer
the impeller, and disposal of settled and floating solids. advice on these topics.
The Flygt standard pump sump can be used as it is, or with
appropriate variations to meet the requirements of Please consult with our engineers to achieve optimum
most installations. pump performance, maximum pump life, and a
guarantee that product warranties are met. The design
The pump and sump are parts of an overall system that also recommendations are only valid for Flygt products. Xylem
includes a variety of structures and other elements such as assumes no liability for non-Xylem equipment.
ventilation systems and handling equipment.
3
Flygt large centrifugal Flygt dry installed pumps are easy to maintain. The motor
and impeller assembly can easily be lifted out of the pump
pumps introduction volute for overhaul and repair. The submersible pump/
motor unit also provides the possibility of a flood proof
Flygt large centrifugal submersible pumps have been used pumping station for safe operation at all times.
in a variety of applications all over the world. Pumps can
be either submerged or dry installed. Applications include
wastewater pumping stations in a variety of sizes as well as
intake stations to treatment plants, storm water pumping,
irrigation, mine applications, shipyards, and more.
4
The design of a sump should not only provide proper • The sump should be as small and as simple as feasible
approach flow to the pumps, it should also prevent the to minimize construction costs, however, a minimum
accumulation of sediments and surface scum in the sump. sump volume may be specified for other reasons, such
The following points must be considered: as to provide for a minimum retention time, or to ensure
• Flow of water from the sump entrance should that only a certain number of pump starts per hour
be directed toward the pump inlets in such a way that occur.
the flow reaches the inlets with a minimum of swirl and
Principles to be adopted in the design of any sump
energy loss.
are given in a number of design guides or “codes of
• In order to prevent the formation of air-entraining practice” – for example, both the American Hydraulic
surface vortices in the sump, the walls must be designed Institute and the British Hydromechanics Research
and built to avoid stagnation regions in the flow. A Association have published such guides. Nevertheless,
properly placed wall close to the inlet can reduce the whenever a new design departs significantly from
tendency toward localized swirl and vorticity. The water established configurations, model tests of the sump and its
depth must also be great enough to suppress surface approaches should be considered.
vortices.
• Although excessive turbulence or large eddies should
be avoided, some turbulence does help to prevent the Xylem standard sump
formation and growth of vortices.
A sump designed in accordance with this brochure is
• Sediment, which could be foul, must not accumulate smaller than a conventional sump. Consequently, there
within the sump. Stagnant regions, or regions of such may be less buffer volume to accommodate transient
low velocity where sedimentation might occur, must be variations of the flow rate. Nor is there extra retention
avoided. A sloping floor and fillets or benching often volume to store the inflow in excess of the total pump
help to prevent sedimentation. For large variations in capacity (the pipe volumes are usually much larger than
flow, part of the sump can be dedicated to low inflows any pump station volume). A proper design of a complete
with a lower floor level and a small pump. Consult Xylem pump station should therefore consider all critical aspects
for an optimum sump design. of operation. Of course, the pump capacity must match the
• Surface scum, floating sludge, and small debris can extreme inflows to minimize the risk of flooding. Often flow
accumulate in any relatively calm region of the water characteristics of the feeding sewer system should also
surface, and this material must be pumped away. The be analyzed.
water level should be lowered as much as possible
at intervals to increase both velocity and turbulence, The control system for the pumps must also provide
however, air should not be drawn into the pump. Please protection in the event of a power failure. Precise level
consult with an Xylem engineer in order to achieve sensors are crucial if the sump volume is minimized in
optimum pumping performance. The occasional accordance with the recommendations in the
increases in flow velocity will also assist in preventing preceding section.
the accumulation of sediment on the floor.
• Station inflow often approaches the wet well at a The discharge pipe work should be designed to
relatively high elevation. In such cases, the liquid may prevent flooding by the return flow when the pumps are
fall a significant distance as it enters the sump. Such a stopped, and also in emergency situations. The effects
drop can also occur whenever the pumps have lowered of possible pressure surges should be minimized by
the liquid level in the sump to the point at which all appropriate design of the control devices.
pumps are about to be switched off. Therefore, the path
between the sump entrance and the pump inlets must
be sufficiently long for the air to rise to the surface
and escape before reaching the pumps. The energy
of the falling water should be dissipated sufficiently
so that excessively high and irregular velocities do not
occur within the sump. This can be accomplished with
properly designed and correctly positioned baffle walls.
5
To avoid pre-swirl into the pump chamber, the
A1 inlet pipe must have a straight length of five
pipe diameters upstream from the sump. The
exact sump design varies with the number of
pumps and pump size.
6
Circular sump Double sump
Construction alternatives
Distributing the flow evenly to all pumps over the width of
the sump can present problems if the number of pumps
B2 is more than four. In such cases, a double sump may be
more suitable.
Reverse oriented pumps Sometimes there is a need to locate the riser pipe in
the center of the stations or locate the outlet in another
direction where reversed pump orientation can be
a solution.
7
Sump dimensions
The sizing diagram is valid for pumping stations up to of the departures does not lead to velocities significantly
four pumps, all of which may be duty pumps. Tolerances higher than those for the standard sump. Flow per pump
of ±10 % on the sump dimensions shown in the table refers to one pump duty point for maximum total flow (in a
below are acceptable provided that the combined effect common pressure pipe).
A
B
C
16,000 D
E
F
1,600
8 80
Dimension [in]
Please note that in this flow region is also sump design recommendations for the mid–range product line are applicable.
A1 Submerged A1 Dry
8
A2 Submerged A2 Dry
B2 Submerged B2 Dry
9
Required sump volume Sump design type A1, A2, B2
The required live volume of the sump, V, i.e. the volume These recommendations are valid for the Flygt pump
between the start level and the stop level of the pump, sump design for two, three, or four pumps, installed
depends upon such factors as the cycle time for the pump, either in a semi-permanent (P) or permanent wet well
T; the pump capacity, Q; and the rate of the inflow, q. (T). It is valid for all four positions of the pumps at all
For one pump and for variable inflow rate, the shortest combinations of pumps in duty, though exceptions in
cycle time occurs if q = Q/2 which gives the minimum the recommendations are made for the straight baffle
required volume of the sump: wall. It is assumed that at least one pump is assigned as
a standby pump, and only in extreme cases will all four
pumps run simultaneously.
The minimum cycle time, (Tminimum) is determined by When the location of the inlet pipe is unsymmetrical, at
the number of pump starts with regard to the mechanical low level, or the last part is less than five straight pipe
stress from the temperature rise in the motor. diameters, higher stop levels to suppress vortices should
T = 3600 / starts per hour be applied according to the recommendations for non-
optimal inflow (see graph: Low level front entry).
For a pumping station with identical pumps, the A1 High level central front entry
required volume is smallest if the pumps start in sequence L-shaped baffle
as the water level rises due to increasing inflow, and stop
in sequence as the water level drops due to decreasing
inflow. To minimize the required sump volume, the last
Submergence to pump inlet
10 One pump stop level
pump to start should be the last pump to stop, i.e.
1st pump stop out of 2 pumps running
cyclic alternation. 8
1st pump stop out of 3 pumps running
6
4
Minimum stop levels 2
The pumps can be stopped at the same water level, but
0
a time delay between the stops is important to avoid 0 10000 20000 30000 40000 Flow / pump
high immediate flow changes and pressure transients in
the discharge pipes. The following minimum stop level
recommendations prevent vortices and air penetration
through to the pump intakes. For a short period of time the
level could be less, e.g. during the sump cleaning cycle. Low level front entry
Off-set front entry
A1 L-shaped baffle
0
0 10000 20000 30000 40000Flow / pump
10
where:
A2 Side entry
NPSHav – Available suction pressure due to atmospheric
L-shaped baffle
pressure, temperature, water level in the sump, and inlet
10
losses.
NPSHreq – The pressure required to obtain a trouble-free
operation in terms of cavitation, the value is determined
Submergence to pump inlet
8
by the NPSH curve for the pump.
6 One pump stop level The available suction head has to be greater than the
1st pump stop out of 2 pumps running suction head required by the pump.
1st pump stop out of 3 pumps running
4 The available suction head in a wet-installed pump
application is:
2
NPSHav = Hatm + Hsump – Hev
0 0 10000 20000 30000 40000
B2 Side entry
Straight baffle wall
10
8
Submergence to pump inlet
11
Installation tips Dry installed submersible pumps
Effects of elbows
Elbows in the piping generate dynamic losses and
swirling flow and should be avoided whenever possible.
To minimize the effects of
the elbows, the pre-swirl 90° 360° 180°
(which could increase
the power requirements
for the pump) should be
located in one plane – as
shown in the 360° and 270°
180° pipe configurations.
12
The inlet bellmouth Installation guidelines for the pump
To accelerate the flow smoothly into the inlet pipe and and its piping
reduce inlet losses, the inlet should be provided with
a bellmouth.
Avoiding vibration and noise
A rotary machine will always be a source of energy for
acoustic/vibrational disturbance. The pump and/or motor
unit can propagate disturbances to the environment that
may excite vibration and cause noise in other parts of
the system, pipes, etc. With wet-well installed pumps, the
medium helps reduce vibration and noise. The design for
dry installed pumps must be more carefully analyzed in
order to reduce these types of problems.
The optimal velocity at the entrance of the bellmouth is In some cases, a totally fixed design is not enough, and
1.7 m/s, (5.6 ft/s) and should be within the following limits. the system or parts of it have to be isolated with rubber
machine feet, a rubber carpet, flexible pipe joints, etc.
13
For more information regarding vibration and noise
prevention for dry installed pumps, please see Xylem’s
Importance of
engineering paper “Noise and vibrations from pumping
installations”.
duty point
In order to achieve the best possible pump operation
Pump anchoring and piping support and maximize equipment life, it is very important to
guidelines select the correct pump for the duty point in question.
The following guidelines can prevent unwanted vibration: The preferred operating region (POR) for most large
centrifugal pumps is between 70 % and 120 % of the Best
1) All parts of the system should be anchored so the Efficiency Point (BEP), as outlined in the Hydraulic Institute
primary disturbances have frequencies below the Standards. The Allowable Operating Region (AOR)
lowest natural frequency of the system, including pump, from BEP for optimal operation of centrifugal pumps in
valves, supports, and pipes. wastewater applications is between 50 % and 125 % of
BEP (unless the curve does not have an operational limit
2) If the pump and foundation are to be insulated from
and sufficient NPSH is available). By running the pump
the pumping station, the following procedure is
outside the AOR the following problems can occur:
recommended:
• Unstable operation.
a) The weight of the foundations should be at least two • Incipient cavitation resulting in impeller erosion, noise
times the weight of the rotating parts. or vibration.
b) Use flexible supports, e.g. machine feet or a rubber
carpet, between the base and the floor or ground. High radial and axial forces
50% – 125% of Qopt
c) Use flexible joints for the pipes.
5) Vertical pipe velocities must be kept at a level that Consult Xylem Engineering if operation outside of the
prevents the settling of solids. The recommended range AOR is required.
is 1.5–2.5 m/sec.
14
Systems Engineering
Xylem offers in-depth expertise in the design and Additional services:
execution of comprehensive solutions for water and • Optimization of pump sump design for our
wastewater transport and treatment. products and specific sites
• Assistance with mixing and aeration specifications and
Our know-how and experience are combined with
design of appropriate systems
a broad range of suitable products for delivering
customized solutions that ensure trouble-free operations • System simulation utilizing computational fluid dynamics
for customers. To do this our engineers utilize our (CFD)
own specially developed computer programs, as well • Guidance for model testing
as commercially available programs, for design and • Guidance for achieving the lowest costs in
development projects. operations, service, and installation
• Specially developed engineering software for system
Scope of assistance includes a thorough
design
analysis of the situation and proposed solutions,
together with selection of products and accessories.
The range of services is comprehensive, but our
philosophy is very simple: There is no substitute for
We also provide hydraulic guidance and assistance
excellence.
for flow-related or rheological issues. Customers turn to
us, as well, for analysis of complex systems for network
pumping, including calculations for hydraulic transients,
pump starts, and flow variations.
15
Xylem |'zīl m| e
1) The tissue in plants that brings water upward from the roots;
2) a leading global water technology company.
FB157-665 • Flygt Design Recommendations For Pump Stations with Large Centrifugal Flygt Wastewater Pumps Brochure • 4/2015 • NACT
We’re 12,000 people unified in a common purpose: creating innovative solutions to
meet our world’s water needs. Developing new technologies that will improve the way
water is used, conserved, and re-used in the future is central to our work. We move, treat,
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their homes, buildings, factories and farms. In more than 150 countries, we have strong,
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of leading product brands and applications expertise, backed by a legacy of innovation.
Xylem, Inc.
14125 South Bridge Circle
Charlotte, NC 28273
Tel 704.409.9700
Fax 704.295.9080
855-XYL-H2O1 (855-995-4261)
www.xyleminc.com
Flygt is a trademark of Xylem Inc. or one of its subsidiaries.
© 2015 Xylem, Inc. APR 2015